JP2010115923A - Cushioning conversion machine and method with stitching assembly - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cushioning conversion machine that allows performing coining, connection, and/or stitching functions to be performed less power, less pinch pressure, and/or more control over the cushioning product's density. <P>SOLUTION: Cushioning conversion stitching/coining members respectively each include a plurality of projections extending radially outward and engaging in mesh during rotation. One stitching member includes a recess and another stitching member includes cutting edges received in the recess to cut a row of slits in overlapped portions of a stock material to form at least one row of tabs for interlocking the overlapped portions of the stock material. The cutting edges are positioned radially between adjacent projections of the second stitching member and circumferentially span less than the circumferential space between adjacent projections. Additionally or alternatively, the projections are formed so that there is exaggerated backlash between mashing projections. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

(Field of Invention)
The present invention relates to cushion conversion machines and methods, and more particularly to improved stitching and / or coining means for such machines / methods.

(Background of the invention)
In the process of transporting an article from one place to another, a protective casing material typically fills any gaps and / or a transport case to cushion the article during the transport process; Or placed in a box. Some conventional protective packaging materials are plastic foam peanuts and plastic bubble packs. While these conventional plastic materials appear to work properly as product cushion supports, they are not without drawbacks. Perhaps the most serious drawback of plastic bubble wrap and / or plastic foam peanuts is the environmental impact. Quite simply, these plastic packaging materials are not biodegradable and therefore they cannot avoid the further increase of the already critical waste disposal problems of our planet. The non-biodegradability of these packaging materials is becoming increasingly important in view of many industries that adopt more progressive measures from the standpoint of environmental responsibility.

  These and other shortcomings of conventional plastic packaging materials have made paper protective packaging materials a very common alternative. Paper is biodegradable, composed of recyclable resources, and is an environmentally responsible choice for conscientious industries.

Sheet form paper may possibly be used as a protective packaging material, and it is usually preferred to convert this paper sheet into a relatively low density pad-like cushioned product. This transformation is described in U.S. Pat. Nos. 3,509,798, 3,603,216, 3,655,500, 3,779,039, 4,026,198, 4,109. , 040, 4,717,613 and 4,750,896 (Patent Documents 1 to 8) , and US Patent Applications Nos. 07 / 533,755 and 07 / 538,181. Converters / methods such as No. 07 / 592,572, 07 / 734,512, 07 / 786,573, 07 / 840,306, and 07 / 861,225 Can be achieved.

  In the converters / methods disclosed in the above identified patents and applications, the cushion product is manufactured by converting the multilayer paper stock material into the desired shape. The cushion product includes a pillow formed by the lateral edges of stock paper wound inwardly to form a pair of twin helices. The central region of this structure is then compressed, connected and / or coined to connect the overlapping edges, thereby having a centrally compressed portion and two side pillows Form a product. This compression, connection, and / or coining is accomplished by a pair of rotating members, each including a plurality of radially outwardly extending protrusions (ie, spur teeth) that engage and engage.

  In order to maintain the integrity of the cushion product, the central portion of the cushion product also further prevents opening or separation of connected parts of the product (this is commonly referred to as “unzippering”). Because of “stitching”. For example, in U.S. Pat. No. 4,937,131 and / or U.S. Pat. No. 4,968,291, the perforations are formed in the coined part of the cushion product by protrusions extending radially outward from the teeth of the rotating member. Is done. In another example, in US Pat. No. 6,035,613, from the radially outer end of an adjacent protrusion (spur tooth) between adjacent protrusions on one of the rotating members in the coined portion. Tabs are formed by cutting edges that are radially inwardly spaced and circumferentially spaced between adjacent protrusions.

US Pat. No. 3,509,798 US Pat. No. 3,603,216 US Pat. No. 3,655,500 US Pat. No. 3,779,039 US Pat. No. 4,026,198 US Pat. No. 4,109,040 US Pat. No. 4,717,613 US Pat. No. 4,750,896

  While the assemblies disclosed in the above identified patents and applications perform their coining, connection, and / or stitching functions properly, there is always room for further improvement, especially those functions that There is room for improvement that can be performed with less power, less pinch pressure, and / or more control over cushion product density.

(Summary of the Invention)
The present invention provides a cushion transducer, wherein the cutting edge used to form the cutting tab in the coined portion of the cushion product has a shortened cutting edge. In particular, this cutting edge does not span the surrounding area of the valley in which they are located (ie the space between adjacent teeth). Concentration of the tab cutting force in a limited area can reduce power demand and / or reduce pinching pressure between rotating members. A concave edge profile can be provided on either side of the cutting edge to enhance the shearing ability of the cutting edge during its approach.

  Additionally or alternatively, the present invention provides a cushioning machine in which the coining member has protrusions formed such that there is an enhanced backlash between the mating protrusions. In particular, the present invention includes the understanding that such an arrangement provides a more obvious coining process, as may be advantageous in certain situations, such as when a higher density pad is desired. In addition, these “emphasized backlash” protrusions provide a direct, noteworthy and predictable relationship between pad density and pinching pressure between coining members, thereby providing a cushioning product The density of can be selectively varied by adjusting the pinching pressure.

The foregoing and other features of the present invention will be fully described hereinafter and particularly pointed out in the claims, and the following description and the accompanying drawings are illustrative of specific examples of the invention. Although an embodiment is described in detail, this embodiment is suggestive and suggests only one of a variety of ways in which the principles of the present invention may be employed.
More specifically, the present invention can relate to the following items.
(Item 1) A cushion changer (15), wherein the cushion changer converts a sheet stock material into a three-dimensional strip of cushion having overlapping portions of the stock material, the conversion assembly (31, 32). Preparation;
The conversion assembly (31, 32) includes a stitching assembly (32), the stitching assembly including a first stitching member (40) and a second stitching member (41), the stitching member Each having a plurality of radially outwardly extending protrusions (220, 234) that engage and engage during rotation of the stitching member (40, 41);
The first stitching member (40) has at least one recess (226), and the second stitching member (41) has the recess (40, 41) rotated during rotation of the stitching member (40, 41). 226) with a cutting edge (237) received in the at least one row for cutting the row of slits (393) in the overlapping portion of the stock material and interlocking the overlapping portion of the stock material. Forming tabs of;
Here, the cutting edge (237) is displaced radially inward from the radially outer end of the adjacent protrusion (234), and the adjacent protrusion (234) of the second stitching member (41). ), And the circumferential spacing is smaller than the circumferential space between adjacent protrusions (234).
(Item 2) A stitching assembly (32) for stitching together overlapping edges of stock material to produce a three-dimensional strip of cushion, the stitching assembly comprising a first stitching member ( 40) and a second stitching member (41), each of said stitching members engaging and engaging during rotation of said stitching member (40, 41), a plurality of radially outwardly extending protrusions Part (220, 234);
The first stitching member (40) has at least one recess (226), and the second stitching member (41) has the recess (40, 41) rotated during rotation of the stitching member (40, 41). 226) with a cutting edge (237) received in the at least one row for cutting the row of slits (393) in the overlapping portion of the stock material and interlocking the overlapping portion of the stock material. Forming tabs of;
Here, the cutting edge (237) is offset radially inward from the radially outer end of an adjacent protrusion (234) arranged radially, where the cutting edge (237) is , Radially disposed between the protrusions (234) adjacent to the second stitching member (41), and the circumferential spacing is the circumferential spacing between the adjacent protrusions (234) Smaller stitching assembly.
(Item 3) A cushion changer (15) or stitching assembly (32) according to item 1 or 2, wherein the cutting edge (237) is located in a radial center relative to the adjacent protrusion (234). ).
(Item 4) The cushion converter (15) or the stitching assembly (32) according to any one of items 1 to 3, wherein an outer diameter of the cutting edge (237) is smaller than an inner diameter of the protrusion (234). ).
(Item 5) The cushion conversion machine (15) or stitching assembly (32) according to item 4, wherein the outer diameter of the cutting edge (237) is larger than the pitch circle of the protrusion (234).
(Item 6) The second stitching member (41) comprises a cutting wheel (232) having a valley alignment portion (236) extending radially in the space between the protrusions (234), and the valley alignment. 6. The cushion changer (15) or stitching assembly (32) according to any of items 1-5, wherein the part (236) has a cutting edge 237.
7. The cushion transducer (15) or stitching of claim 6, wherein each of the valley alignment portions (236) further comprises a concave edge profile surrounding each radial side of the cutting edge (237). Assembly (32).
8. The cushion transducer (15) or stitching assembly (32) of claim 7, wherein each of the valley alignment portions (236) has a relief (238) to form the concave edge profile.
(Item 9) The relief (238) has a semi-circular cutout that extends from one radial edge of the cutting edge (237) to at least the radial end of the valley alignment portion (236). Cushion converter (15) or stitching assembly (32) according to claim 1.
(Item 10) A cushion conversion machine (15) comprising a conversion assembly (31, 32) for converting sheet stock material into a three-dimensional strip of cushion having overlapping portions of stock material;
The conversion assembly (31, 32) includes a coining assembly (32), and the coining assembly includes a first coining member (40) and a second coining member (41). Each of the members has a plurality of radially outwardly extending protrusions (220, 234) that engage and engage during rotation of the stitching member (40, 41);
A cushion converter, wherein the protrusions (220, 234) are formed such that there is an enhanced backlash between the engaging protrusions.
(Item 11) The highlighted backlash is arranged such that its top land contacts the bottom land of another stitching member, and its depth direction is perpendicular to the root circle of the other member. Cushion converter (15) according to item 10, having a radial clearance on both radial sides of the protrusion, if done.
12. The cushion transformation of claim 10 or 11, wherein the protrusion has a semi-circular bottom land, a generally pointed top land, and / or an increasing fillet that forms a parabolic valley between adjacent teeth. Machine (15).
(Item 13) The first coining member (40) has at least one recess (226), and the second coining member (41) is rotating the coining member (40, 41). Having a cutting edge (237) received in the recess (226) to cut a row of slits (393) in the stock material overlap to interlock the stock material overlap. 13. Cushion converter (15) according to any of items 10 to 12, forming at least one row of tabs.
(Item 14) The cutting edge (237) is radially disposed between adjacent protrusions (234) of the second coining member (41), and a circumferential extension is adjacent to the protrusion ( 234). Cushion converter (15) according to item 13, which is smaller than the circumferential space between.
(Item 15) The cushion converter (15) according to any one of items 10 to 14, further comprising a control mechanism for controlling a pinch pressure between the coining members (40, 41).
(Item 16) A cushion product made by the machine (15) or stitching assembly (32) according to any of items 1-15.
(Item 17) A dunnage product (375) formed from stock material of at least one layer (377, 378, 379) having an overlap portion (282), wherein the overlap portion is an inwardly directed recess. (389) with one row of outwardly directed recesses (388) and at least one row of tabs (391), the height of the tabs (391) being the height of the recesses (388) Dunnage products that are lower than the height.
(Item 18) The tab (391) is defined by a smooth edge slit, laterally spaced, and from a layer of stock material in a direction opposite to a relatively adjacent recess of the row of recesses. The dunnage product (375) of item 17, wherein the product is punched.

FIG. 1 is a side view of a cushion transducer with the side panel of the machine housing closest to the observer removed to allow observation of internal machine parts, which compresses the central band of the cushion product A stitching assembly that is coined, coined and / or connected. FIG. 2A is a side view of a rotating member of a stitching assembly, ie, a female stitching member. FIG. 2B is an exploded edge view of the female stitching member. FIG. 2C is an assembled edge view of the female stitching member. FIG. 3A is a side view of another rotating member of the stitching assembly, the male stitching member. FIG. 3B is an exploded edge view of the male stitching member. FIG. 3C is an assembled edge view of the male stitching member. FIG. 4A is a representative view of a toothed flat disc member forming part of a female stitching, as viewed from line 4A-4A in FIG. 2B. FIG. 4B is a representative view of a small diameter annular flat disk member forming part of the female stitching member, as viewed from line 4B-4B in FIG. 2B. FIG. 5A is a representative view of a toothed flat disk member forming part of a male stitching member, as viewed from line 5A-5A in FIG. 3B. FIG. 5B is a representative view of a large diameter annular flat disk member forming part of the male stitching member, as viewed from line 5B-5B in FIG. 3B. FIG. 5C is a representative view of a small diameter annular flat disk member forming part of the male stitching member, as viewed from line 5C-5C in FIG. 3B. FIG. 6 is a schematic view of a cushioning product having its central band connected by a stitching assembly. 7 is a cross-sectional view taken along line 7-7 in FIG. FIG. 8 is a partial plan view of two parts of a stitching member, shown with these parts in tight engagement. FIG. 9 is a partial plan view similar to FIG. 8 except showing a modified version of the tightly engaged parts. FIG. 10 is a schematic cross-sectional view of the central band of the cushion product when the modified part shown in FIG. 9 is used in a stitching assembly.

(Detailed explanation)
Referring now in detail to the drawings and referring first to FIG. 1, a cushion transducer 15 according to the present invention is illustrated. The machine 15 has a holder 16 at its upstream end (to the left in FIG. 1) for the supply of a roll or the like of sheet stock material. This stock material preferably consists of three superimposed piles or layers of 30 pound kraft paper wound into a hollow cylindrical tube that is biodegradable, recyclable and reusable. Alternatively, the stock material preferably consists of two superimposed piles of 50 pound kraft paper wound into a hollow cylindrical tube. This cushion converter 15 converts the stock material into strips with side pillows separated by a central band. This strip is connected along its central band to form a coined strip of cushion product that can be cut by cutting into sections or pads of the desired length.

  The machine 15 includes a housing 18 having a base plate or wall 20, side plates or walls 21, and end plates or walls 22 that collectively form a frame structure. The base wall 20 is substantially flat in shape and rectangular. The housing also includes a top wall 23 that forms an enclosure with the base, side and end walls.

  Base wall 20 and side wall 21 are centrally located at the upstream end of the housing and have inward edges that form a rectangular border around a relatively large rectangular stock inlet opening 25. This border may be viewed as an end plate or wall that extends perpendicularly from the upstream edge of the base wall 20. It should be noted that the terms “upstream” and “downstream” are used herein in relation to the direction of flow of stock material through the machine 15. This end plate 22 extends vertically from a location near the downstream end of the base wall 20 but inwardly from the downstream end of the base wall 20. This end plate 22 is substantially rectangular and flat and includes a dunnage outlet opening.

  The housing (or frame) 18 also includes a front cover or plate 26 that extends vertically from the downstream edge of the base wall 20. Therefore, the end plate 22 and the front plate 26 constrain the upstream end and the downstream end of the box-shaped extension at the downstream end of the housing 18. Thus, the front plate 26 can be a door-like structure that can be selectively opened to access the cutting assembly parts of the cushion converter 15.

  The machine 15 includes a stock supply assembly 30, a forming assembly 31, a supply / connection assembly 32 powered by a stitching member drive motor (eg, an electric motor (not shown)), a cutting motor (eg, an electric motor (not shown)). And a post-cutting or cutting guide assembly 34. Stock supply assembly 30 includes an inlet roller 36 and separators 37a-37c and is attached to the upstream side of housing 18 (or more specifically, the upstream end plate or wall). The forming assembly 31 is disposed within the housing downstream of the stock supply assembly 30 to form the stock material into a continuous three-dimensional strip of dunnage having portions of the stock material that overlap along the central region of the strip. To work. A supply / connection assembly 32 is disposed downstream of the forming assembly 31 and attached upstream of the downstream end plate 22. A sawing or cutting assembly 33 is mounted on the opposite site or downstream side of the downstream end plate 22. A motor is preferably mounted on the base wall 20 which may include a transverse mounting plate 38 that forms part of the base wall or plate 20. This motor is disposed on the opposite side of the forming assembly 31. The post-cut assembly 34 is disposed downstream of the cut assembly 33 and is mounted on the front cover 26. Reference may be made to US patent application Ser. No. 08 / 386,355 for a cutting assembly similar to that illustrated, or to US patent application Ser. No. 08 / 110,349 for another type of cutting assembly.

  The exemplary machine feed / connect assembly 32 performs two functions. This feed / connect assembly connects the overlapping portions of stock material and maintains the three-dimensional shape of the dunnage strip. The feed / connection assembly also functions to feed the stock material through the machine by pulling from the stock feed assembly and through the forming assembly 31. These dual functions are performed by a pair of rotating stitching members and in particular gear-like members 40 and 41 and are described in more detail below. In an exemplary embodiment in which the present invention is illustrated, one of the gear-like members 40 is mounted on the shaft 43 and is rotationally driven by a feed motor, while another gear-like member 41 is a floating shaft 44. It is an intermediate car carried above. The drive gear-like member 40 rotates about an axis fixed with respect to the front panel 22, while another gear-like member translates toward and away from the drive shaft 43. And held on a floating shaft guided by a guide slot in the guide 45. The floating shaft, and thus the floating gear-like member, is elastically biased towards the drive gear-like member by a spring 46 or other suitable elastic biasing means. This spring force can be adjusted to change the clamping force applied by the geared member from the forming assembly to the strip of stock material passing therebetween.

  In operation of the machine 15, the stock supply assembly 30 supplies stock material to the forming assembly 31. Forming assembly 31 causes inward winding and formation of sheet stock material to form the side pillows of the continuous strip of cushion. Feed / connect assembly 32 advances stock material through the machine and also connects the central strip to form a connected dunnage strip. As this connected dunnage strip moves downstream from the feed / connect assembly 32, the cutting assembly 33 cuts the dunnage strip into sections or pads of the desired length. This cut or cut pad then moves through the assembly 34 after cutting.

  The machine 15 described so far is substantially the same as the machine described in more detail in US Pat. No. 5,123,889, for further details of the general arrangement and operation of this machine. Reference can be made. However, it is noted that the exemplary forming assembly 31 is of the type described in pending US patent application Ser. No. 08 / 386,355. The forming assembly also includes a guide ramp 47 to which a shape chute 48 is attached, the guide ramp having an extended guide surface portion 49 that extends from the downstream end of the shape chute proximate to the gear-like members 40 and 41. .

  With additional reference now to FIGS. 2 and 3, stitching members 40 and 41 are shown in detail. As seen in FIGS. 2A-2C, the female stitching member 40 extends radially outwardly, such as an exemplary spur gear tooth around its periphery, preferably in the form of a tooth around its periphery. A protrusion 220 is provided. The tooth 220 is divided into a central segment 222 and an outer or side segment 224 by an annular recess 226. The shaft segments 220 and 224 and the recess 224 are preferably arranged symmetrically with respect to the central plane of the female member 40.

  Another stitching member, male stitching member 41, includes a central segment 230 and an outer segment 233 that is axially adjacent to inner segment 232, and outer segment 233 is the inner segment. Each of 232 is adjacent to the outside. The central segment 230 and the outer segment 233 have a plurality of radially outward protrusions 234 about their perimeters, which are preferably teeth 220 of the central segment 222 of the female stitching gear 40 (FIGS. 2A-C). , And teeth such as exemplary spur gear teeth for meshing with outer segment 224. The spacing between the teeth 234 of the central segment 230 and / or the outer segment 232 can be seen as valleys 235.

  As best seen in FIG. 3A, the inner segment 232 is also referred to as a cutting wheel, each having a portion 236 aligned with a valley 235 between the teeth 234 of the central segment 230 and / or the outer segment 232. . This valley aligned portion 236 includes a cutting edge 237 and a relief 238 on each side of the cutting edge 237. While the valley-aligned portion 236 spans the surrounding space between the protrusions 234, the cutting edge 237 has a smaller peripheral span than the surrounding space between adjacent protrusions 234. Preferably, and as illustrated, the cutting edge 237 is a peripheral edge that is concentric with the root circle of the tooth 234. Relief 238 is in the form of a semi-circular notch extending from one radial edge of cutting edge 237 to at least the radial end of valley alignment 236. In this manner, a concave edge profile surrounds each radial side of the cutting edge 237 at each valley alignment portion 236.

  During rotation of stitching members 40 and 41, trough 235 (between teeth 234 of male stitching member 41) receives teeth 220 of female stitching member 40 (FIGS. 2A-C). As a result, during rotation of the stitching members 40 and 41, the valley alignment 236 of the cutting wheel 232 moves past the synchronously moving teeth of the female stitching gear 40, and the cutting edge 237 in turn into the recess 226. Accepted. (Each cutting wheel 232 has a thickness that is slightly less than the width of each groove 226 in the female gear 40). Since the cutting edge 237 does not extend around the perimeter of the valley aligned portion (eg disclosed in US patent application Ser. No. 08 / 607,607), this cutting force is concentrated in a limited section, thereby Reduces power demand and / or allows reduction of pinching pressure between stitching members 40 and 41. The notch 238 is not directly involved during the cutting process, but the provided concave edge profile is believed to increase the shearing capability of the cutting edge 237 during its access to the recess 226.

  The central toothed segment 222 (FIGS. 2A-2C) of the female gear 40 and the central toothed segment 230 (FIGS. 3A-3C) of the male gear 41 are each centered annularly aligned with each other and with equal width. There may be grooves 239 and 240.

  For ease of manufacture, the gears 40 and 41 are preferably employed as desired if the disk member is economical (eg, typically steel (other suitable materials (typically metal) are also desired). It is preferably formed by a stack of axially juxtaposed disk members having a thickness that allows it to be formed)) by stamping from a sheet or plate, laser cutting). The preferred gear illustrated in FIGS. 2 and 3 consists essentially of five different flat disk members 243-247, all of which are required to fit a pair of disk members and a groove between the disk members. Except for slight variations, it preferably has about the same uniform thickness. However, different numbers of disk members can be used, which can be quite different thicknesses. For example, if desired, a single thicker disk member can be used in place of multiple disk members forming a single axis segment.

  Disk members 243 and 244 have a spur gear cross-section as shown in FIGS. 4A and 5A, with their teeth 260 and 261 extending radially outward from respective hubs 264 and 265 and spaced circumferentially. Form a vacant protrusion. Disk members 243 and 244 have one or more holes 267 and 268 for connecting pins and central holes 269 and 270 for attachment to the shaft, respectively. As shown, the disk member 243 (which is a driven gear) used to form the female gear 40 is evenly spaced in three circumferential directions in its hub 264 to connect the pins. It has a drilled hole 267 and a central hole 269 with a key slot 273 that fits the key onto the drive shaft. Another disk member 244 used to form the male gear 41 may have, for example, two diametrically opposed connecting pin holes 268 that must be driven as in the illustrated preferred embodiment. Does not have a key slot. Apart from the connection hole and the central hole, the disk members are preferably otherwise identical (size and shape).

  Disk members 245 and 246 have a circular shape, and disk member 247 has a generally circular shape with a fan-shaped edge to form a cutting edge 237 and a notch 238. Disk members 245 and 246 are preferably the same diameter, and preferably have a diameter equal to the diameter of hub 264/265 from which the protrusions or teeth 260/261 of disk member 243/244 are radially outward. extend. The disk member 247 preferably has a diameter that is greater than the diameter of the disk members 245 and 246. The disk member 245 used to form the female gear 202 has a connection hole 278 and a keyed center hole 279, similar to the toothed disk member 243. Similarly, the disk member 246/247 used to form the male gear has a connection hole 282/283 and a central hole 286/287 as in the toothed disk member 244.

  Eight toothed disk members 243 and four small diameter circular disk members 245 are assembled together to form female gear 40 as seen in FIGS. 2B and 2C. Three toothed disk members 243 (FIG. 4A) are stacked with their teeth aligned with each other to form each outer segment 224. The central segment 222 is formed by two smaller circular disk members 245 sandwiched between two toothed disk members 243 having their teeth aligned with each other and the teeth of the outer disk segment 224. The smaller circular disk member 245 spaces the toothed gear member 245 and thus forms an annular central groove 240 therebetween. Each side segment 224 is spaced from the central segment 222 by a small diameter disk member 243 thereby forming an annular groove or groove segment 246 between the central segment and the outer segment. This disc member is held together by a connecting member 290, such as a rivet or pin, extending through a hole 267/278 in the disc member 243/245 that is axially aligned to receive the connecting rivet. Other suitable means may be employed to secure the disk members together. For example, the disk members can be welded together and / or to the support shaft.

  Eight toothed disk members 244, two small diameter circular disk members 246, and two large diameter disk members 247 are assembled together to form a male gear 41 as shown in FIG. Three toothed disk members 244 are stacked together so that their teeth are aligned with each other to form each outer segment 233. The central segment 230 is formed by two smaller circular disk members 246 sandwiched between two toothed disk members 244 whose teeth are aligned with each other and the teeth of the outer disk segment 233. A smaller circular disk member 246 separates the toothed gear member 244 and thus forms an annular central groove 239 therebetween. Each side segment 233 is spaced from the central segment 230 by a larger diameter disk member 247, thereby forming a punching segment 232 between the central segment and the outer segment. These disc members are held together by a connecting member 293, which is, for example, a rivet or pin that extends through a hole in the disc member that is aligned to receive the connecting rivet. Again, other suitable means (eg, welding) can be utilized to secure the disk members together. A bushing 294 may extend through the central hole 270/286/287 of the disk member as shown.

  As is apparent here, the gears 40 and 41 rotate synchronously. This is because the central and outer segments of these gears are engaged. This intermeshing gear pulls the overlapping side edges of the stock material between them and at the same time forms a depression or indentation of the stock material, thereby coining the stock material (mechanically permanent) To deform). At the same time, a cutting edge 237 that spans the teeth 234 (FIG. 3A) of the adjacent toothed section moves over the teeth 220 (FIG. 2A) of the female gear 40. At the nips of these gears, the juxtaposed cutting edges and female gear teeth then move adjacent parts of the stock material in the opposite direction while the cutting edges cooperate to create a shearing action and overlap. A slit through each of the layers is formed on each side with a smooth edge tab formed in this manner, and this tab is punched by a punch segment 237. Forming the step.

  With reference now to FIGS. 6 and 7, a cushioning product according to the present invention is shown schematically as 375. The cushion product comprises at least two, preferably three or more layers (panels) 377-379 of sheet-like material, which are preferably biodegradable, renewable and reusable. Including kraft paper. Layers 377-379 are interleaved and / or overlapped so that their lateral edges are folded over the center and visible at 382. This overlapping, alternating portion 382 is stitched together along a central seam or band 383. The stitching pattern produced by the stitching gear includes a central row 387 in which outwardly directed dents 388 alternate with inwardly directed dents 389. The central row of recesses is bounded on each side thereof by a row 390 of tabs 391. These tabs are defined by laterally spaced slits 393 and are recessed or punched from a layer of stock material in a direction opposite to the relatively adjacent recesses in the central row.

  The disk members that make up the gears 40 and 41 can be assembled in different patterns, as may be desired for a particular application. The outer segment of the stitching gear can be constituted by a single tooth disk member. This is because it may be desirable to form narrower stitching. Conversely, the number of toothed disk members can be increased, providing a wider segment (s). Similarly, the number of spacer disk members and punch disk members can vary, giving the resulting cushion strip different properties. According to a specific preferred example, two of the toothed disk members 244 can be overlapped together, wherein the teeth are aligned with each other to form each outer segment 233, and the central segment 230 includes two pairs of It may be formed by two smaller circular disk members 246 sandwiched between toothed disk members 244, the teeth of these toothed disks being aligned with each other and with the teeth of the outer disk segment 233.

  Additionally or alternatively, the placement of the stitching members 40 and 41 relative to the cushion product can be modified if necessary or desired. In the illustrated embodiment, the female stitching member 40 is in direct contact with the overlapping side edge 382 of the stock material layers 377-379 so that the tab 391 is from that side of the cushion product (upper side in FIG. 6). Protruding. However, depending on the specific preferred example, the stitching members 40 and 41 can be reversed (with appropriate modifications to fit the drive / idle arrangement of the shafts 43 and 44) or the orientation of the forming assembly 31 can be reversed. obtain. By such reversal or inversion, the male stitching member 41 is in direct contact with the overlapping edge of the stock material layer and the tab 391 projects outward from the opposite side of the cushion product (the lower side of FIG. 6).

  Additionally or alternatively, the shape and / or size of the disk members that form the stitching members 40 and 41 can be modified. With particular reference to the cutting disk 247 of the male stitching member 41 (or cutting wheel 232 if the stitching member 41 is made in a different manner), its diameter modifies the depth of the tab slit, And / or can be selected to change the pinch pressure between the stitching members 40 and 41. The circumferential extent of the cutting edge 237 can also be modified and / or the shape of the relief 238 can also be changed.

  With particular reference to the toothed disk members 243 and 244 (or the segment including the protrusions 220 and 234 if the stitching members 40 and 41 are made in a different manner), the number of protrusions 220/234 is Can be increased / decreased. The illustrated stitching members 40/41 each have eleven protrusions 220/234, whereby the disks 243/244 each have eleven teeth 260/261. Modifications may be made in accordance with specific preferred embodiments so that each of the stitching members 40/41 has ten protrusions 220/234. This modification in the protruding pattern, of course, requires a smaller modification to the cutting wheel 232 and / or the cutting disk 247.

  Additionally or alternatively, the shape of the protrusions 220 and 234 can be changed. Depending on the specific preferred embodiment, the shape of the protrusions 220 and 234 may be changed to provide a “larger slop” or “emphasized backlash” between the engaging protrusions. In the most convenient gear arrangement this is probably undesirable. However, the present invention encompasses applications where such an arrangement provides a clearer coining, as may be advantageous in certain situations, such as where a higher density pad is desired.

  In addition, the “highlighted backlash” protrusion provides a direct, prominent and predictable relationship between the coining profile between the stitching members 40 and 41 and the pinch pressure. Since the impression profile of the cushion product corresponds to its density, the density of the cushion product can be selectively varied by adjusting the pinch pressure between the stitching members 40 and 41. For example, the cushion converter 15 can be modified to include a control mechanism that is operatively connected to the coining gear so that the operator can selectively select the density of the cushion product on demand. Can be changed. This control mechanism may include an accessible member on the outside of the housing so that the operator can easily adjust the density of the cushion product, for example as described in International Patent Application No. PCT / US96 / 10800. . Additionally or alternatively, the pinch pressure of stitching members 40 and 41 can be controlled by a microprocessor. In either case, the floating shaft arrangement shown in FIG. 1 can be replaced with the arrangement shown in US patent application Ser. No. 08 / 487,179 to more easily adjust the pinch pressure between members 40 and 41. It may be preferable to enable

  A preferred possible modification of the shape of the protrusions 220 and 234 will be described in connection with replacing the gear disks 243 and 244 (FIG. 6) with gear disks 1243 and 1244 (shown in FIG. 7). However, it is possible with the present invention to incorporate modified protrusions into stitching members 40 and 41 made in separate elements, which are contemplated by the present invention. Furthermore, the modified protrusions may be advantageous for coining only connections and / or drilling / coining connections.

  In the illustrated stitching member 40/41, the teeth 260 and 261 of the gear disks 243 and 244 are formed in a conventional gear fashion so that when tightly engaged together, they have the appearance shown in FIG. . In the context of the present invention, “tightly meshed” means that the top land of the protrusion 260 contacts the bottom land between the protrusions 261. During actual operation of the cushion changer 15, the layer of stock material is between the protrusions 220 and 234 formed by the teeth 260 and 261 so that these teeth mesh very tightly. Furthermore, even conventional drying gears are usually not designed to mesh together so tightly. Accordingly, it should be understood that the illustrations of FIGS. 8 and 9 are not provided for purposes of illustrating the intended operational arrangement.

  In FIG. 8, the disks 243 and 244 are shown in tight meshing, where the depth direction of the teeth 260 is located perpendicular to the root circle of the disk 244. In this tightly meshed state, the tooth 260 contacts the side of two adjacent teeth 261, thereby closing the spacing between the teeth 261. This contact is due to the shape of the teeth 260/261, particularly the flat bottom land, the flat top land, and the abrupt fillet radius.

  In FIG. 9, the disks 1243 and 1244 are shown in tight engagement, where the depth dimension of the tooth 1260 is located perpendicular to the root circle of the disk 1244. Even in this tightly meshed state, teeth 1260 do not contact the sides of two adjacent teeth 1261. This “spacing” or “slop” is a reconstructed shape of teeth 1260/1261 (particularly, a semicircular bottom land, a generally pointed top land, and a gradual increase that forms a parabolic valley between adjacent teeth. Due to the fillet radius).

  If the stitching members 40 and 41 are modified to include highlighted backlash protrusions, the stitching pattern created thereby is shown in FIG. As shown, this stitching pattern still remains in the center row 387 of outward / inwardly oriented recesses 388/389, and adjacent outwardly directed recesses 388 (when viewed from the top of FIG. 10). Between the tabs 391 extending in the longitudinal direction. Since the profile of the recess 388/389 is more obvious, the height of the tab 391 is lower than the height of the recess 388/389.

  While the invention has been illustrated and described with respect to certain preferred embodiments, it will be apparent to those skilled in the art that equivalent changes and modifications will occur to upon reading and understanding this specification. For example, the stitching gear can be used in other types of machines and methods for stitching overlapping portions of one or more layers of stock material. The present invention includes all such equivalent changes and modifications.

15 Cushion converter
16 Holder
18 Housing
20 Base plate
22 End plate
23 Top wall
25 Entrance opening
26 Front plate
30 Stock supply assembly
31 Forming assembly
32 Supply / connection assembly
33 Cutting assembly
34 Cutting guide assembly

Claims (6)

A cushion conversion machine (15) comprising a conversion assembly (31, 32) for converting sheet stock material into a three-dimensional strip of cushion having overlapping portions of stock material;
The conversion assembly (31, 32) includes a coining assembly (32), and the coining assembly includes a first coining member (40) and a second coining member (41). Each of the members has a plurality of radially outwardly extending protrusions (220, 234) that engage and engage during rotation of the stitching member (40, 41);
A cushion converter, wherein the protrusions (220, 234) are formed such that there is an enhanced backlash between the engaging protrusions. The emphasized backlash is located when its top land is placed in contact with the bottom land of another stitching member and its depth direction is perpendicular to the root circle of the other member 2. A cushion conversion machine (15) according to claim 1, having radial clearance on both radial sides of the protrusion. Cushion converter (15) according to claim 1 or 2, wherein the protrusions have semi-circular bottom lands, generally pointed top lands, and / or incremental fillets that form parabolic valleys between adjacent teeth. ). The first coining member (40) has at least one recess (226), and the second coining member (41) is in the recess () during rotation of the coining member (40, 41). 226) with a cutting edge (237) received in said at least one row for cutting a row of slits (393) in said stock material overlap and interlocking said stock material overlap. Cushion converter (15) according to any of claims 1 to 3, which forms a tab. The cutting edge (237) is disposed radially between adjacent protrusions (234) of the second coining member (41), and a circumferential extension is between adjacent protrusions (234). The cushion conversion machine (15) according to any one of claims 1 to 4, wherein the cushion conversion machine (15) is smaller than the circumferential space. The cushion conversion machine (15) according to any one of claims 1 to 5, further comprising a control mechanism for controlling a pinch pressure between the coining members (40, 41).

Images